service repair manual

1. K1008703BE Shop Manual
Copyright 2008 Doosan
Doosan reserves the right to improve our products in a continuing process to provide the best possible
product to the market place. These improvements can be implemented at any time with no obligation to
change materials on previously sold products. It is recommended that consumers periodically contact their
distributors for recent documentation on purchased equipment.
This documentation may include attachments and optional equipment that is not available in your
machine's package. Please call your distributor for additional items that you may require.
Illustrations used throughout this manual are used only as a representation of the actual piece of
equipment, and may vary from the actual item.
Shop Manual
K1008703BE
Serial Number 5221/5117 and Up
DX480LC
DX520LC

2. Table of Contents
Page 1
1Table of Contents
Safety
Track Excavator Safety......................................................................... SP000907
Specifications
Specification for DX480LC/520LC........................................................ SP001761
General Maintenance
General Maintenance Procedures ...................................................... SP000016
Standard Torques................................................................................. SP000813
Upper Structure
Cabin .................................................................................................... SP001737
Counterweight....................................................................................... SP001762
Fuel Tank.............................................................................................. SP001763
Fuel Transfer Pump (Opt)..................................................................... SP000021
Swing Bearing....................................................................................... SP001856
Swing Reduction Gear.......................................................................... SP001764
Lower Structure and Chassis
Track Assembly .................................................................................... SP000171
Engine and Drive Train
Drive Coupling (Main Pump)................................................................. SP000026
Hydraulics
Hydraulic System Troubleshooting, Testing and Adjustment ............... SP001765
Accumulator.......................................................................................... SP000028
Center Joint (Swivel)............................................................................. SP000181
Cylinders............................................................................................... SP000193

3. Table of Contents
Page 2
Swing Motor.......................................................................................... SP000194
Travel Motor (With Gearbox) ................................................................ SP000185
Main Pump............................................................................................ SP000186
Gear Pump (Fan Cooling Drive) ........................................................... SP000208
Main Control Valve ............................................................................... SP000187
Remote Control Valve (Work Lever / Joystick)..................................... SP000189
Travel Control Valve (With Damper)..................................................... SP001743
Fan Motor (Vane Type)......................................................................... SP000209
Fan Cooling Flow In-Out Change Valve ............................................... SP000207
Solenoid Valve Assembly ..................................................................... SP001622
Breaker EPPR Valve (Opt) ................................................................... SP000192
Hydraulic Schematic DX480LC/520LC................................................. SP001766
Electrical System
Electrical System .................................................................................. SP001767
Electrical Schematic DX480LC/520LC ................................................. SP001854
Attachments
Boom and Arm...................................................................................... SP001851
Bucket................................................................................................... SP001853

4. SP000185
Page 41
Travel Motor (With Gearbox)
TRAVEL MOTOR SPEED
REDUCTION GEARBOX
DISASSEMBLY
1. Drain gear oil and remove travel motor and O-ring.
2. Remove motor flange (8 socket bolts, M16 x 35). Figure
64.
3. Remove O-ring from motor flange. Figure 65.
4. Remove O-ring from hub groove. Figure 66.
Figure 64
3034
Figure 65
3035
Figure 66
3036

5. SP000185Travel Motor (With Gearbox)
Page 42
5. Attach disc (B, Figure 67) to spring retainer; fasten pusher
(A) to hub and install screw rod (C).
6. Remove retaining ring from hub groove using pliers. Figure
68.
7. Remove jig and retaining ring. Figure 69.
Figure 67
3037
Figure 68
3038
Figure 69
3039

6. SP000185
Page 43
Travel Motor (With Gearbox)
8. Remove spring retainer. Figure 70.
9. Pull spring from groove. Figure 71.
10. Blow air into brake port hole and remove brake piston
using pliers. Figure 72.
11. Remove brake shaft. Figure 73.
Figure 70
3040
Figure 71
Figure 72
Figure 73

7. SP000185Travel Motor (With Gearbox)
Page 44
12. Remove disc. Figure 74.
13. Remove O-ring and backup ring. Figure 75.
14. Turn reduction gear assembly over and remove 2 plugs
(M22 x 1.5). Figure 76.
15. Remove 16 socket bolts (M14 x 40). Figure 77.
Figure 74
Figure 75
Figure 76
Figure 77

8. SP000185
Page 45
Travel Motor (With Gearbox)
16. Remove end cover, using puller. Figure 78.
17. Remove O-ring from end cover groove. Figure 79.
18. Remove first sun gear. Figure 80.
19. Remove first planetary gear assembly. Figure 81.
Figure 78
Figure 79
Figure 80
Figure 81

9. SP000185Travel Motor (With Gearbox)
Page 46
20. Remove second sun gear. Figure 82.
21. Remove second planetary gear assembly. Figure 83.
22. Remove third sun gear. Figure 84.
23. Remove bolts (4, M 30 x 150) from third planetary gear
assembly. Figure 85.
Figure 82
Figure 83
Figure 84
Figure 85

10. SP000185
Page 47
Travel Motor (With Gearbox)
24. Remove bolts. Figure 86.
25. Separate hub from reduction gear housing, using press
and stopper. Figure 87.
NOTE: Do not remove main ball bearing.
26. Remove third shift assembly from hub. Figure 88.
Figure 86
Figure 87
Figure 88

11. SP000185Travel Motor (With Gearbox)
Page 48
27. Remove bushing from hub using a jig. Figure 89.
28. Remove bearing inner race and spacer from hub, using
puller. Figure 90.
Figure 89
Figure 90

12. SP000185
Page 49
Travel Motor (With Gearbox)
29. Remove gasket. Figure 91.
Figure 91

13. SP000185Travel Motor (With Gearbox)
Page 50
CLEANING AND INSPECTION
(WEAR LIMITS AND
TOLERANCES)
For general cleaning and inspection procedures, refer to
"General Maintenance Procedures" section.
Gearbox Inspection
1. If a gear is damaged, replace the damaged gear and the
interlocking gear next to it. If one planetary gear is
damaged, replace the entire planetary gear assembly.
2. Replace O-rings.
3. Apply grease to assembly side of O-rings to make
assembly easier.

14. SP000185
Page 51
Travel Motor (With Gearbox)
TRAVEL MOTOR SPEED
REDUCTION GEARBOX
REASSEMBLY
1. Install seal to jig. Figure 92.
2. Install jig to housing. Figure 93.
3. Clean seal surface. Figure 94.
Figure 92
Figure 93
Figure 94

15. SP000185Travel Motor (With Gearbox)
Page 52
4. Install seal to hub using jig used in Step 1. Figure 95.
5. Apply lubricant to seal surface. Figure 96.
6. Support ball bearing housing with spacers (1 and 2, Figure
97) and install bearing into housing. Install spacer between
balls, noting diameter shown in illustration.
7. Install upper balls and upper housing. Figure 98.
Figure 95
Figure 96
Figure 97
Figure 98

16. SP000185
Page 53
Travel Motor (With Gearbox)
8. Install hub to housing. Figure 99.
9. Press hub into housing using a press and a stopper. Figure
100.
10. Install four bushings using a press. Figure 101.
11. Assemble planetary gear assembly. Figure 102.
Figure 99
Figure 100
Figure 101
Figure 102

17. SP000185Travel Motor (With Gearbox)
Page 54
12. Install four planetary gear assemblies, using press. Figure
103.
13. Tighten gear box of planetary gear assembly to 150 Nm
(110.7 ft lb). Figure 104.
14. Assemble third shift sun gear. Figure 105.
15. Assemble the second shift reduction assembly. Figure
106.
Figure 103
Figure 104
Figure 105
Figure 106

18. SP000185
Page 55
Travel Motor (With Gearbox)
16. Place planetary gear carrier on hub. Figure 107.
17. Press planetary gear carrier into hub. Figure 108.
18. Apply loctite to planetary gear carrier fastening bolts.
19. Install and tighten bolts. Figure 109.
NOTE: In next step, the O-ring and backup rings are
different. Be careful not to switch them.
20. Install O-ring to end cover. Figure 110.
Figure 107
Figure 108
Figure 109
Figure 110

19. SP000185Travel Motor (With Gearbox)
Page 56
21. Install end cover to housing.
NOTE: Apply Loctite 243 to bolts and torque to 10 Nm
(7.38 ft lb). Figure 111
22. Tighten plugs to 6 - 8 Nm (4.42 - 5.90 ft lb). Figure 112.
23. Turn housing over and install second shift sun gear. Figure
113.
24. Install first shift planetary gear assembly. Figure 114.
Figure 111
Figure 112
Figure 113
Figure 114

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21. SP000185
Page 57
Travel Motor (With Gearbox)
25. Install first shift sun gear. Figure 115.
26. Install O-ring (1, Figure 116) and backup ring (2) into hub
groove.
NOTE: The O-ring and backup rings are different. Be
careful not to switch them.
27. Install brake shaft while turning the reduction gear
assembly. Figure 117.
Figure 115
Figure 116
3086
Figure 117

22. SP000185Travel Motor (With Gearbox)
Page 58
28. Install brake disc assembly, starting with a copper disc
(seven pieces) and alternating with steel discs (six pieces).
Figure 118 and Figure 119.
29. Install jig to hub and insert spring retainer disc under left
side of retaining ring. Figure 120.
30. Install retaining ring using retaining ring pliers. Figure 121.
Figure 118
Figure 119
Figure 120
Figure 121

23. SP000185
Page 59
Travel Motor (With Gearbox)
31. Install O-ring to hub groove. Figure 122.
32. Place brake piston inside hub being careful not to damage
seal. Figure 123.
33. Insert springs into brake piston holes. Figure 124.
34. Install retainer disc. Figure 125.
Figure 122
Figure 123
Figure 124
Figure 125